Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1VD-FTV FUEL

PRECAUTION

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

REMOVE THERMOSTAT

REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

REMOVE NO. 1 WATER BY-PASS PIPE

REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)

REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)

REMOVE TIMING CHAIN COVER PLATE

REMOVE NO. 1 FUEL PIPE

REMOVE FUEL SUPPLY PUMP

FUEL SUPPLY PUMP - REMOVAL

NOTICE:

When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head or intake manifold, it is necessary to replace the injection pipes with new ones.

w/ DPF:
When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work ().

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

Disconnect the cables from the negative (-) main battery and sub-battery terminals.

3. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

()

4. REMOVE THERMOSTAT

()

5. REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

()

6. REMOVE NO. 1 WATER BY-PASS PIPE

Fuel Supply Pump - Removal. 1VD-FTV FUEL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

7. REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)

Disconnect the 3 fuel tube connectors ().

Detach the 3 clamps and remove the fuel tube.

8. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)

w/o Viscous Heater:

Remove the 2 bolts and timing gear cover insulator.

w/ Viscous Heater:

Remove the timing gear cover insulator.

9. REMOVE TIMING CHAIN COVER PLATE

Remove the 4 bolts, cover plate and gasket.

10. REMOVE NO. 1 FUEL PIPE

Remove the union bolt, fuel pipe and 2 gaskets.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

11. REMOVE FUEL SUPPLY PUMP

Using a wrench, hold the crankshaft.

NOTICE:

Do not turn the crankshaft counterclockwise.

If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt ().

Torque:
108 N*m{ 1101 kgf*cm, 80 ft.*lbf}or more

Remove the set nut.

Disconnect the fuel temperature sensor connector.

Using a 6 mm hexagon wrench, remove the bolt.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Loosen the 2 nuts.

Disconnect the pump from the supply pump drive gear.

Install SST (No. 1 adapter) to the timing chain cover.

SST
09950-50013(09951-05010,09952-05010,09953-05020,09954-05031,09955-05010)

Text in Illustration
*1	SST (No. 1 adapter)
*a	Service Hole

NOTICE:

Do not use any tools in this procedure.

Rotate the supply pump gear so that the service holes are aligned with SST (No. 1 adapter) as shown in the illustration.

Using SST, disconnect the pump from the supply pump drive gear.

NOTICE:

When removing or installing SST, do not push the supply pump gear.

Apply lubricant to the threads and tip of SST (center bolt) before using it.

Remove the 2 nuts.

NOTICE:

Do not hold the supply pump by the parts indicated by the arrows in the illustration, as this may result in deformation, damage and fuel leakage.

The pump must be kept horizontal.

Fuel Supply Pump - Removal. 1VD-FTV FUEL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*A	w/ DPF	*B	w/o DPF
*1	Fuel Temperature Sensor	*2	Suction Control Valve
*3	Fuel Pipe	*4	Drive Shaft

Remove the O-ring from the supply pump.